Composite article and method of making it



Feb. 20, 1951 u w. c. GREGORY 2,542,134

COMPOSITE ARTICLE AND METHOD OF MAKING IT Filed July 26, 1944 Patented Feb. 20, 1951 UNITED STATES PATENT oFFIce COMPOSITE ARTICLE AND, METHOD'OF MAKING IT Waylandc C. Gregory, Bound'Brook; N. J.

Application July 26, 1944, Serial No..5.46,611

13 Claims.

This invention relates to composite articles, and`v in particular to such articles embodying lens-forming areasor portions of glass, of suite able color, providedwith' internal fracturesformingglight-reflecting;facets or. surfaces imparting to the aforesaid' areas. or portionsy gem-like or jewel-likeproperties of.' great decorative, artistic, and' aesthetic value.

It is the object of this invention to provide new and improved articles ofthe class described wherein the lens-formingV internally fractured areas or'portions'are secured in bases, or frames of suitable material such as ceramic materialor metal,l providing protection therefor and/or facilitating fabrication of other objects or articles made up of a' plurality of such compositeY articles.

It is4 a further object of this invention to provide new and improved methods of making the aforesaid articles and in particular to form the aforesaid light`transmitting areasY or portions-ofjtheinternally fractured glass therein.

This application is'a continuation-in-part of my copending application Serial No. 426,584 filed January "13, 1942 which matured into U. S. Lettersv Patent No. 2,357,399 granted SeptemberY 5, 1944. 'I'hese'and'other objects and advantages Aof the inventionl will clearly appear from the following,

description taken with the accompanying drawingand the appended claims.

In theV drawing:A

Fig: 1 is a top plan view illustrating the making of a composite article, according to this invention, with a frangible member or projection severable to form a light transmitting area ordene;Y

Fig. 2 isv a section taken substantially'on the liney 2-2 of Fig. 1, cross-hatching being omitted from certainportions of the article in the interest of;A clearness of disclosure;

Fig. 3 is a view similar to Fig. 2, of a modification thereof;

Fig. 4 is a View, in section, illustratingv the formation of a composite article with a hollow space thereinV for accommodating a source of illumination, orl the like;

Fig. 5 is a` View, similar to Fig. 1, of another modicationwherein a removable ring is utilized:

in forming the frangible lens-forming projection or member;I

Fig. 6- is a section taken substantially on the linen 6--6- of Fig. 5 and showing the parts separated; subsequent to severance of the lens-form-V ing projection or member;

Fig. 7'i's aview similar-to' Figs. 2 and 3f but illustrating the formation, in a split or separable mold, of a composite article comprising an annulus into which a body of internally fractured glass isformed, with a decorative or design element at one surface; and

Fig. 8 is a plan View, partly in section, ofthe structure of Fig; 7 asseen from the plane indicated'by the line 8--8 of' Fig. 7; looking downwardly.

In the embodiment' illustrated'in Figs. 1' and?, the composite articley comprises a body. i9' of ceramic material, for instance, with an annular side wall Il and a bottom portion lhaving an' opening l2 extending' therethrough. The wall of the opening I2 is preferably providedv'with an inwardly directed'iiange I4 fora purpose'which will appear hereinafter.

In forming the above describe-dY article, the body I9 is'placedupon a ceramic orrefractory base I 5` having'an undercuty recess It" therein, which recess is aligned withA the above described opening l2. Thereafter a body Il of" glass is cast inntliespace formed jointly by the opening |22 andthe recess I'. 'Ihe'optional iiange I4 enhances the bond between theglass' i7 andthe body lll by'` increasing the` bonding' area and alsoprovides a mechanical interlock between the glass and'V the" ceramic orrefractory material of theA body Ill'.

The` undercut recess" I: iny the blockY orr base l5forms a projection l'weakened at the severing plane I9 along Whichit'maybe broken off to providea clear light transmitting surfacefwhereby theglass-body'l-lforms, in eifect, a light transmittingwindow or lens between the interior of the body Il!l and the rear thereof', thefracture surfaces'being clear andneeding no grinding or other treatmentV to alloWf light to pass` there-- through.-

While the articleshereinxdescribed andillusn trated embody-each but av single lens, as described above, it is of courseto beunderstood.thatmany such lenses may/be provided in a single article, and the arrangement. thereof maybe variedfor instance to form theV outlineof Variousdecorative symbols, initials, figures, etc.

As described in my copending application Serial No. 426.584, led' January 13, 1942which matured in U. S. LettersfPatent No. 2,357,399 granted September 5, 1944, the decorative quality of glass areas of'such composite articles may/be greatly increased by` the provision of internal fractures therein.

These fractures form light reflecting surfaces" or facets, generally` haphazardly-arrangedj andiv reflect light in such manner as to impart a gemlike or jewel-like quality to the glass areas which thus present, generally speaking, life and sparkle to such degree as to suggest sheets of precious jewels bonded to the articles. For this reason, fractures 25 are provided in the interiorfof the glass VI, and substantially throughout.

The fractures 20 may be formed in the glass body I1 by shrinkage of the glass, on cooling, beyond the shrinkage of the portions of the body l bonded or fused thereto as described in the aforesaid application Serial No. 426,584; in such casethe projection I8 will be removed or severed from the main body I 'I thereafter. Alternatively, the fractures 20 may be formed in the glass by localized thermal shock induced by rapid cooling. For instancev the body I0 and glass may be heated several hundred degrees Fahrenheit above normal room temperature, either before or after the projection has been severed, and the whole assembly rapidly cooled or a cooling medium applied to localized portions in order to induce in the glass I'I such internal stresses as will form therein fractures 20 of such size and location as are desired.

The casting of the glass in the body Ill and fusing (i. e., bonding) of the glass to the ceramic body I0 may be accomplished after assemblage of tbe body I Il and base I5 as shown inFig. 2, by placing glass, glass forming materials or a mixture thereof in the interior of the body I 0 and recess I6 and ring the assemblage, i. e., subiecting the assemblage in a kiln, for instance, to such heat for such time as to fire the ceramic body while melting the glass and fusing it to the ceramic bonding surfaces. Alternatively, the body Ill may be fired or partly fired before introduction of the glass. In such case, the glass may also be introduced in molten condition to the interior of the body I0 and the recess I6 substantially at or above the fusing temperature of the glass.

While the body I0 is illustrated as formed of ceramic material, other suitable materials, suitable for bonding to glass, may be used, as for instance, metal. Where metal is so used, suitable ground coatings or fluxes may be applied to the bonding surfaces to aid in bonding or fusing the glass to these surfaces. Other facetforming means may also be provided in the glass body as, for instance, metallic flakes, particles or the like suspended therein.

As shown in Fig. 3, the projection I8 may be eliminated, or omitted by substituting for the ceramic or refractory base, block, or base block I5 and its undercut recess I6 a base, base block or plate 2| of metal, optionally provided with means such as 22 for locating and retaining the body I0 in position on the base or plate 2|. Where the base block is refractory, the bonding surface or interface will be rough and opaque, requiring further treatment before light can pass therethrough. y

In such case, the glass for forming the body is supplied in molten condition to the interior of the body I0 at substantially glass fusing temperature, the base or block 2| being at sufficiently lower temperature to prevent fusing of the glass thereto. If desired the base or block 2| may be provided with suitable means for maintaining its temperature within a desired range, not shown, or the surfaces may be treated to prevent fusing of glass thereto. It is to be noted that the glass forming surface of the plate 2| obviates necessity for polishing or otherwise finishing the rear or lower surface of the glass body I'I.

In the embodiment illustrated in Fig. 4, the body 25, corresponding with the above described body IU, is of substantially uniform section from end to end, being provided with a plurality of internal flanges 2S corresponding functionally with the above described flange I4. Though the body 25 is illustrated as formed of ceramic material or the like, it may, of course, be formed of metal as described above.

The base member or base plate 28 is provided with suitable seats 29 engaging the body 25 to retain it in position on the base or plate 28, and a core 30 of suitable form projects upwardly into the interior of the body 25 and into the body of glass bonded therein. The core is illustrated as formed of metal integrally with the base 28 but it may be formed separately therefrom and detachable, if desired. Likewise, in the latter case, it may be made of refractory or other frangible material, formed in the glass body and thereafter removed. The base or plate 28 may also be formed of such materials.

By forming a body I'| of glass on the interior of the body 25 with internal facet forming means such as fractures 2B as described above, with a space such as 2I within the interior of the glass Il, a source of illumination may be inserted in the aforesaid space to produce varied artistic effects as of great masses of jewels of any desired color since the color of the glass may be varied as desired.

. As an alternative to the undercut recess I5 provided in the base I5 (Figs. 1 and 2) a removable ring 3| with an undercut central .recess 32 may be interposed between the base or plate I5 and the body II). The ring may be frangible or sectional (and reusable) and like the base I5 and body Ill may be formed of refractory or ceramic or like material, or of metal. As shown in Fig. 6, a weakened section is formed along the plane represented by the line 33 facilitating severance of the projection I8 either prior to removal of the ring 3|, as shown in Fig. 6, or thereafter.

As in the embodiment of Fig. 4, the condition in which the glass (i. e., glass forming material) is fused or bonded to the body will depend upon the nature of the body, the base, and the ring or core associated therewith as described above in the description of the embodiments of Figs. 1, 2 and 3.

As shown in Figs. '7 and 8, such composite articles may be formed in split or separable molds or presses of known form. The press shown in Fig. 7 comprises the relatively movable parts 35 and 36 each provided with means such as grooves 37 to retain the body I0 in proper alignment with respect to the parts 35 and 36. These parts are preferably formed of metal, as shown, but as will be readily understood, they may be formed of other materials.

When the parts 35 and 3B are advanced totheir ultimate position adjacent one another, the annular wall I of the body I0 cooperates therewith to form therewithin a space of predetermined volume. By supplying to the interior of the body lll, as it rests upon the lowermost, supporting part 35 of the press, when the upper most part 3B of the press is withdrawn upwardly, as shown in Fig. 7, a given quantity of molten glass, the press may be Yclosed to form a body I1 of desired thickness.

Optionally suitable means 38 may be provided on one of the press members for molding a suitable design element in a surface of the body H.

If desired, suitable conventional means may be provided for maintaining the temperature of the parts and 36 of the mold or press within suitable limits for repeated, speed, operation irrespective of the temperatures of the body I0 and the molten glass which temperatures must be maintained rather close together and within relatively narrow limits in order that secure bonding (i. e., fusing of the glass to the internal surfaces of the body ID) may be obtained.

If desired, the body Il (Figs. 7 and 8) may be formed separately with the groove for receiving the flange lli of the body Il! molded therein. Thereafter, the flange I4 may be spun into the groove for mechanical attachment of the glass body Il and the metal body l!) either 'before or after the facet forming internal fractures are provided in the glass body I7.

In each of the above described articles, the facet forming internal fractures may result from localized thermal shock as described above. This internal fracturing by localized thermal shock is,

generally, independent of the bonding area and/or security of fusion between the glass and material of the base. However, in order to secure internal fracturing on cooling by reason of differential shrinkage between the glass and base material, it is necessary that the security and extent of the fusion or bonding be sufficient to permit the cohesion of the glass to be overcome by the stresses induced therein during cooling without substantial damage to, or deterioration of, the adhesion (fusion) between the glass and the base material.

In the following claims, the terms glass and vitreous material are to be broadly interpreted as including preiired or fritted glass, raw glass,

or glass forming materials convertible to molten glass by the heat of fusion or bonding, or mixtures of such fritted glass, raw glass or glass forming materials in any suitable proportions, which mixtures will be converted by the heat of fusion to fusible molten glass. This glass will bond to (i. e., fuse with) the base or frame and thus become so firmly secured thereto, or integrated therewith that internal cracking or fracture of the glass may occur subsequently, by reason of localized application of thermal shock, or by reason of differential shrinkage upon cooling, without destruction of the bond between the glass and the material of the base or base member.

It is of course to be understood that the above description is merely illustrative and in nowise limiting and that I desire to comprehend within this invention such modifications as are included within the scope of the following claims.

Having thus fully described my invention, what I claim as new and desire to secure by Letters Patent is:

l. A composite article comprising a base with an aperture communicating with opposite sides thereof, and a glass body rigidly mounted in said aperture and forming a decorative lens, said glass body having therein haphazardly arranged internal fractures forming individually perceptible light reflecting facets imparting a gem-like quality to the lens formed thereby.

2. The structure defined in claim 1 wherein said base is formed of material capable of having glass fused thereon.

3. A composite article comprising a frame with a space open at opposite sides, and a glass body rigidly mounted in said space and forming a decorative lens, said glass body and the vengaging portion of said frame being `provided with means forming a mechanical interlock therebetween, and said glass body having therein haphazardly arranged internal fractures forming light reflecting facets imparting a gem-like quality to the lens formed by said glass body.

4. A composite article comprising a base of ceramic material with an aperture communicating with opposite sides thereof, and a glass body having oppositely Apositioned surfaces, said glass body being rigidly mounted in said aperture and bonded to said ceramic base and forming a decorative lens, said glass body having therein haphazardly arranged internal fractures forming light reflecting facets said fractures extending substantially continuously between said oppositely positioned surfaces, thereby imparting a gem-like quality to the lens formed by said glass body.

5. A composite article comprising a metal frame with an aperture communicating with opposite sides thereof, and a glass body rigidly mounted in said aperture forming a decorative lens, said glass body having therein haphazardly arranged internal fractures extending continuously throughout said body forming light reflecting facets imparting a jewel-like quality to the lens formed thereby.

6. A composite article comprising a base formed of material capable of bonding with glass and with an aperture communicating with opposite sides thereof, a glass body in said aperture integral with said base an`d forming a decorative lens, and a design element formed adjacent one surface of said lens, said glass body having therein internal fractures forming individually perceptible-internal light reflecting facets imparting a gem-like quality to the lens formed by said glass body.

7. A composite article comprising a frame of material capable of bonding with glass and with an opening therein, and a glass body rigidly mounted and bonded by fusing to the sides of said opening and to said frame to form a light transmitting decorative lens, said glass body having therein a space accommodating a source of illumination, said glass body being provided with internal fractures forming internal light reflecting facets imparting a live gem-like appearance to the lens formed by said glass body.

8. The method of forming a composite article embodying a glass lens member provided with internal fractures forming light reecting facets imparting a jewel-like quality thereto comprising, forming a base capable of being bonded to glass by fusion of the glass and having at least one aperture extending therethrough, forming in said aperture a body of glass with internal fractures therein forming said facets and having a frangible projection extending beyond one side of said aperture, and severing said frangible projection to form a clear surface area at one side of said lens for passage of light therethrough.

9. The method of forming a composite article embodying a glass lens member provided with internal fractures forming light reflecting facets imparting a jewel-like quality thereto comprising, forming a base capable of being bonded with glass by fusion of the glass and having at least one aperture extending therethrough, forming in said aperture a body of glass having a frangible extension projecting beyond one side of said aperture, severing said frangible extension to form a clear surface area at one side of'Vsaid-Vvlens 'for UNITED STATES( PATENT passage of light therethrough, and thereafter Number Name Y Date forming said light reflecting facets in said lens. 250 378 I Meyer A Dec 8 1881 10. The method defined in claim 8 wherein said 284657 Edison "Sept '19 1882 base is formed of ceramic material. 5 273371 Lindsle; Mar 6 1888 11. The method defined in claim 8 wherein said 885270` Jacobs "June '28 1888 base is formed of metal.

12. The method dened in claim 9 wherein seid 1 gg ggigr et al' JL 1g gg base is formed of ceramic material. 1803552 Mddendor' Oct '19 1928 13. The method defined in claim 9 wherein said 10 18 482312 Bruzzone Ma'l, 8 1932 base is formed 0f metal- 210171294 Branson Feb. '161 1937 WAYLANDE C- GREGORY- 2,073,254 Redman Mar. 9, 1937 2,345 278 Monack Mar. 28, 1944 REFERENCES CITED l .t 15 2,351,399 Gregory Sept. 5, 1944 e The following references are of record 1111' he y FOREIGN PATENTS file of this patent: Y

Number Country Date 522' Great Britain 1899 

1. A COMPOSITE ARTICLE COMPRISING A BASE WITH AN APERTURE COMMUNICATING WITH OPPOSITE SIDES THEREOF, AND A GLASS BODY RIGIDLY MOUNTED IN SAID APERTURE AND FORMING A DECORATIVE LENS, SAID GLASS BODY HAVING THEREIN HAPHAZARDLY ARRANGED INTERNAL FRACTURES FORMING INDIVIDUALLY PERCEPTIBLE LIGHT REFLECTING FACETS IMPARTING A GEM-LIKE QUALITY TO THE LENS FORMED THEREBY. 